Shower bath cabinet



CLGSETS, SIN 'v AND SPLUQNS.

S. H T1 A B Dec. 29, 1936. P. w. KERR SHOWER BATH CABINET Filed May 23,1935 me sentons.

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Patented Dec. 29, 1936 UNITED STATES PATENT OFFICE This inventionrelates to shower bath cabinets, and among other objects aims to providea socalled knock-down shower cabinet which can be produced at lower costthan heretofore and will have a quality and decorative appearance inhar- Y mony with standard bathroom design.

The nature of the invention may be readily understood by reference toone construction embodying the invention and illustrated in theaccompanying drawing.

In said drawing:

Fig. 1 is a small scale perspective view of a' shower bath cabinet;

Fig. 2 is a fragmentary plan section of the cabinet on a larger scaleshowing approximately onehalf of the area of the cabinet, the sectionbeing taken approximately on the broken plane 2-2 Y of Figs. 1 and 3;

Fig. 3 is a vertical section taken on the plane 3-3 of Fig. 1; and

Fig. 4 is a fragmentary section through the edge of the receptor at thedoor opening, being taken on the plane 4-4 of Fig. 1.

One of the characterizing features of bathroom design is porcelainenamel both in white and attractive colors. For most fixtures thismaterial has proved entirely satisfactory and it is now so firmlyestablished as a standard material that its use in practicallyessential. For shower bath cabinets, particularly the sheet metal andknock-down types, which are fabricated largely of sheet metal, porcelainenamel has not heretofore been entirely satisfactory, and itsapplication to sheet metal has been diicult and in some casesimpractical.

The major problems in this connection have been (1) chipping or crackingof the relatively brittle enamel because of the flexibility of the sheetmetal; (2) warping of the sheet metal side walls under the enamelingheat, particularly at the connecting flanges or joints, which makesassembly difficult and tends to cause leakage at the joints; and (3) theslipperiness of a porcelain enameled receptor. Among other objects thepresent invention has solved these problems in a practical andeconomical way. The illustrative shower` bath cabinet which embodies theinvention, both harmonizes with present bathroom practices and designand may be produced at relatively low cost.

As here shown, the shower bath cabinet comprises the receptor ID formingthe base of the cabinet and the superposed sheet metal side walls II, inthis case embodied in connected sections, forming the enclosure exceptfor the entrance or l cabinet side walls and the receptor.

doorway I2 which may be closed either by a curtain or door as desired.The receptor is here shown resting upon a rectangular base frame I3whose height is at least suiiicient to accommodate the dish of thebottom I4 and may advantageously be somewhat higher, as in the presentinstance, to allow space for a portion of the drain outlet fixture I5which is connected to the receptor at its center or lowest point.The'receptor is centered on the frame by downwardly extend--4 ingprojections I6 preferably torch-welded to the under face of the receptoradjacent its corners.

The receptor is preferably formed of sheet enameling iron or steel ofsufficient thickness to provide, in conjunction with the receptor sidewalls or flanges I1 (which are in this case integral with the bottom),an adequately stiif or rigid structure. Sheet metal of from sixteen tofourteen gauge has been found suitable for this purpose.

The side walls I I are likewise formed from sheet enameling iron orsteel but may be of a somewhat lighter gauge, twenty to sixteen gaugebeing satisfactory. As here shown, the side walls are formed in threesections, namely, two side sections I8 and I9 and a back section 20. Theside sections include also front wall portions 2I formed with sidestiles 22 to frame the door opening I2.

As shown more particularly in Fig. 3, the side walls are supported byand connected to the receptor side walls I'I by finishing screws 23which penetrate the side walls and receptor and enter nuts 24 on theexterior. A leak-proof joint between the side walls and receptor isprovided by a gasket 25 preferably of molded rubber which is locatedbetween the cabinet side walls and the receptor and is sufficientlyresilient to compensate for any inequalities (frequently produced bywarping in the enameling process) between the Preferably the gasket isfinished at its upper edge with a head or bead 26 which partiallyextends over the side of the receptor and at its lower end with a liange21 which extends under the lower edge of the side wall. The upper edgeof the receptor wall is advantageously finished by bending over themetal as at 28 to form a smooth and finished upper edge.

The nuts 24 are advantageously positioned and concealed by a partlyclosed sheet metal channel 29 extending around the receptor. As shown inFigs. 3 and 4, the channel is of a size to hold the nuts againstturning, and is provided with an upwardly extended curved flange 30constructed and A arranged to be inserted in the space 3| under themargin 28 by which the channel is frictionally held in place. The nutsare held in position longitudinally of the channels in any appropriatemanner as by crimping the inner channel flange (see Fig. 2) on oppositesides of the nuts to prevent their sliding in the channel. The nuts maythus be located accurately opposite the registering perforations in thereceptor and cabinet side walls through which the fastening screwseventually pass.

The corners of the channels 29 are advantageously enclosed by cornermembers 32 having projections 33 which extend upwardly into the space 3|in which they are held by a cement or other appropriate means. Adjacentthe corners the flanges 28 are cut or mitered away to accommodate theprojections 33. The channel and corner member fastening means needfunction only during the assembly of the cabinet since after thefastening screws 23 are positioned, the latter will serve to support theexterior channel 29. The latter may be formed either in one piece or ina separate section for each side of the receptor. In either case, thesupporting corner elements 32 serve to cover any joint at the corner.These channels may also advantageously serve as finishing strips justbelow the folded-over receptor flanges, and for that purpose are formedof suitably decorative material such as brass, stainless steel, nickelplate or the like.

As will presently appear, the location of the nuts in accurate positionfacilitates the assembly of the cabinet from within the receptor withoutrequiring access to the exterior, and thereby permits the erection ofthe cabinet in small or confined spaces where access to the back or sidewalls of the receptor is impossible.

The cabinet side wall sections are in this case connected at the tworear corners of the cabinet. As here shown, the adjoining side flangesof the sections are inwardly offset as at 34 and are joined by aninterior corner strip 35 having curved side edges 36 which embrace andconceal the offset portions. The joint is rendered leak-proof by gaskets31 which lie between the corner strip and the inwardly offset margins.Preferably such gaskets are in the form of molded rubber channels whichembrace the inwardly offset margins and extend, on the interior, to theedges of the corner strip and are there engaged by the inwardly curvedmargins of the strip. The corner strip is here shown appropriatelysecured in place by oval head finishing screws 38 which thread intoanchor bar 39, the side flanges 40 of which lie behind or outside theinwardly offset side wall margins, between which, in the presentinstance, the other side of the rubber gaskets extend. When the sidewall margins and the corner strip are tightly clamped together, theresilient rubber gaskets serve to form a leak-proof jointnotwithstanding inequalities caused by warping of the side wall edgesduring the enameling process. process the temperature is raised to about1600" F. and it is generally impossible to prevent some slight warpingof the side walls particularly at the free side flanges. Despite themagntiude of distortions due to warping and indeed recognizing theimpossibility of preventing warping, the joint structure is such as tomake assembly and eventual alignment of the parts possible withoutdamage to the enamel. In the particular construction shown, the sidewalls and joint strip may be assembled and initially connected together(regardless of warped side flanges) simply by placing the In this cornerstrip 35 in its appropriate position and entering the screws 38 into theanchor bar 39, the screws being long enough to allow for considerableinitial separation of the parts due to warping. Thereafter the screwsserve to draw the parts tightly together, flattening out any warping atthe joint. It should be particularly noted that hammering or otherviolent methods of forcing the parts into alignment to form the cornerjoint is avoided, thereby protecting the porcelain enamel againstchipping or cracking. These and other improvements herein disclosed,make practical the use of porcelain enamel on the sheet metal sidewalls.

The corner strip 35 is advantageously dished or countersunk at the screwholes to seat the oval screw heads and thus render them relativelyinconspicuous. The rubber gaskets also prevent enamel to enamel contactor enamel to metal contact which might result in chipping of the enamel.

The rear corners of the cabinet structure may be advantageously finishedby exterior corner strips 4| having inwardly turned flanges 42 whichembrace the edges of anchor bar 39 and are thereby held firmly in place.be of appropriate decorative material such as brass, stainless steel,nickel plate or the like. The lower ends of the strips extend into thereceptor and are seated against the rubber gaskets 25.

It will be noted from the foregoing that the corner joints are formedwithout the necessity of penetrating the side walls with fasteningmeans, thereby allowing slight relative movement between the parts andgreatly facilitating assembly since accurate alignment of parts isunnecessary.

Nevertheless, substantial movement or displacement of the side wallmargins is prevented by the extremities 36 of the corner strip whichpass behind the inwardly extending offsets 34 of the side walls and thusprevent their withdrawal without however preventing the aforesaid slightmovement of the side wall flanges in the joint.

As shown in Figs. 1 and 3, the cabinet may be covered with an enameledsheet metal top whose flanges are bolted to the side walls.

The side wall sections and receptor are coated with vitreous porcelainenamel according to approved practices for enameling sheet metal ware.The so-called wet process may be employed to advantage. coat is sprayedon the metal side walls and either dried at room temperature or in adrying oven for about an hour and a half at a temperature of about 150F. The ground coat is then burned or fired in an enameling oven forabout six minutes at about 1550a F.

All the margins, inside and out, of the side walls are then coated withso-called flexible enamel which is available only in dark colors. Blackis employed since it can be so used as to provide a decorative effect.The width of the black stripe 43 is made wider than the margin coveredby the corner and top and bottom joint structures, to leave a stripe ofabout one-eighth of an inch visible. After drying, the enameled marginsare burned at about 1550 F.

Thereafter the color or nish coat is applied by spraying on enamel ofthe desired color which is brushed or otherwise applied adjacent themargins to leave a uniform width of black margin visible. The color coatis dried and then burned in the enameling oven at about 1600 F. forabout six minutes. The greater flexibility of the black enamel on themargins allows the latter to be The corner strips may In that processthe ground or gripl flexed sufficiently to flatten any warping at theLib corner joints and also avoids breaking or cracking of the enamelfinish in ordinary handling and usage in which the edges of the metalare flexed more severely than any other portion of the side wallsections.

The receptor is preferably finished to simulate generally theconventional terrazzo or other shower receptors. After the ground orgrip coat has been applied by dipping or spraying and then dried, thecolor or finish enamel is stippled on so that it falls in relativelylarge drops (which spread to irregular areas 44 about three-sixteenthsof an inch in diameter) which in contrast with the dark ground coat 45,give an attractive finish. The coarse stippling or speckled effect asaforesaid may be produced by lowering the air pressure on the spray gunso that the enamel is deposited in relatively large drops spacedsubstantial distances apart (see Fig. 2). If a uniform or plain colorcoat be desired, the iinish enamel coat may be sprayed on the receptorin the usual way; but in that event it is preferable first to fire theground coat. With either method of finishing, the receptor with theground coat and subsequently applied and dried finish or speckle coat isthen placed in the enameling oven and subjected to a temperature ofabout 1600 F. for about six minutes.

The receptor bottom is advantageously made slip-proof by uniformlydistributing thereover granular material such as ine silica sand andanchoring the same in the enamel. In Fig. 2 an attempt has been made toillustrate the sand particles 46 by fine dots but it will be understoodthat exact illustration is impossible since' the particles of sand arerelatively inconspicuous and are individually much smaller thanillustrated. Moreover, their concentration is much greater than shown.Indeed, the effect is somewhat like fine sandpaper except that theparticles of sand are preferably not as sharp as in sandpaper and arenot so concentrated. When the surface is wet, the appearance of thebottom of the receptor is not noticeably different from that of theinterior faces of the receptor side walls which are not renderedslip-proof.

The sand is advantageously applied by uniformly sprinkling the same overthe bottom of the receptor at some stage in the enameling process priorto the firing of the top or finish coat, which in this instance is thevstipple or speckle coat. Uniform distribution can readily be effectedby a vibrating screen on which the sand is placed. The texture of thenon-slip surface depends on the following: (l) The coarseness oriineness of the sand; (2) its sharpness; (3) the degree to which theparticles of sand are submerged in the enamel; and (4) the amount orconcentration of the sand grains. Preferably the sand should be clean toeliminate fine dust particles which serve no useful function and onlydull the iinish. A satisfactory non-slip surface the sand in the enamelmay be secured by sprinkling the sand uniformly on the bottom after thefinish or speckle coat has been applied but before the latter has beendried. Those particles of sand which lie on the ground coat between thespeckles 44 or finish coat, do not become embedded until the firingoperation, at which time the ground coat softens and allows the grainsof sand to embed themselves. The grains of sand lying, in the specklesor finish coat are of course somewhat more deeply embedded in the enamelbut are not entirely embedded nor glazed over. Too deep embedding f theparticles should be avoided since it increases the possibility that theywill be glazed over in firing and thus to a great extent lose theirproperty of rendering the receptor bottom slip-proof.

Obviously the invention is not limited to the details of theillustrative construction since these may be variously modified.Moreover, it is not indispensable that all features of the invention beused conjointly since various features may be used to advantage indifferent combinations and subcombinations.

Having described my invention, I claim:

l. A shower bath cabinet of the character described comprising incombination sheet metal side walls, coated with porcelain enamel, asheet metal receptor having side flanges supporting said side walls,said receptor being coated with porcelain enamel and the bottom thereofhaving particles of sand partly embedded in said enamel.

2. A receptor for shower bath cabinets comprising in combination anintegral sheet metal structure having a bottom and side iianges, saidbottom having thereon porcelain enamel, and grains of sand partlyembedded in the enamel coat to provide a non-slip surface.

3. A shower bath cabinet of the character described comprising incombination a sheet metal receptor having marginal side flanges, saidflanges being bent down to form a double thickness of metal at the topedge of the receptor, sheet metal side walls carried by said receptoriianges, bolts passing through said side walls and flanges to connectthe same and carrying nuts on the exterior of said receptor, and anexterior finishing strip covering the nuts for said bolts and havingflanged portions which lie between the nuts and said receptor.

4. A shower bath cabinet of the character described comprising incombination a sheet metal receptor having marginal side flanges, sheetmetal side walls carried by said receptor flanges, bolts passing throughsaid side walls and flanges to connect the same and carrying nuts on theexterior of said receptor, and a channel-shaped exterior finishing stripcoveringthe nuts for said bolts and provided with a ange lying betweenthe nuts and the face of said receptor.

5. A shower bath cabinet comprising in coinbination a metal receptor,side walls rising from said receptor, said receptor having an enamelsurface with grains of sand or the like embedded therein to provide anon-slip surface.

PAUL W. KERR.

